Systems and methods for sprayable hemp-based compositions

ABSTRACT

Described herein are compositions comprising hemp, minerals, and water. Such compositions may be used in construction, building materials, insulation, etc. Such compositions may be sprayed, poured, cast, molded, etc.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Nonprovisional patentapplication Ser. No. 17/206,954, filed Mar. 19, 2021; which claims thepriority benefit of U.S. Provisional Patent Application Ser. No.62/992,539, filed Mar. 20, 2020, the contents of each of which areherein incorporated by reference in their entirety.

TECHNICAL FIELD

This disclosure relates generally to the field of hemp, and morespecifically to the field of hemp-based compositions. Described hereinare systems and methods for sprayable hemp-based compositions forachieving a fireproof, high strength, and/or insulation material thatassists with construction and plumbing needs but may otherwise be usedfor any other building, construction, reinforcement, etc. needs.

BACKGROUND

Traditionally, in different applications, hemp-based concretecompositions have been poured into moldings or frames which are laterremoved and utilized as bricks or slabs after the product is hardened.This process is labor intensive resulting in higher costs, a need formore personnel, and a greater risk of potential error. Described hereinare sprayable hemp-based compositions.

SUMMARY

One aspect of the present disclosure is directed to a compositioncomprising hemp, at least one mineral, and water. In some embodiments,the at least one mineral comprises one or more of: potassium, magnesium,calcium, or phosphorus. In other embodiments, the at least one mineralcomprises one or more of: lime, hydraulic lime, or a concrete selectedfrom the group consisting of: concrete, mortar, stucco, grout, andPortland cement. In some embodiments, pH of the minerals is betweenabout 7 and about 10. In other embodiments, a pH of the minerals isbetween about 7.5 and about 8.5.

In some embodiments, an amount of potassium in the minerals is betweenabout 25 ppm and about 100 ppm. In other embodiments, the amount ofpotassium in the minerals is between about 25 ppm and about 75 ppm. Infurther embodiments, the amount of potassium in the minerals is betweenabout 50 ppm and about 70 ppm.

In some embodiments, an amount of magnesium in the minerals is betweenabout 250 ppm and about 600 ppm. In other embodiments, the amount ofmagnesium in the minerals is between about 250 ppm and about 500 ppm. Infurther embodiments, the amount of magnesium in the minerals is betweenabout 300 ppm and about 400 ppm.

In some embodiments, an amount of calcium in the minerals is betweenabout 3,000 ppm and about 9,000 ppm. In other embodiments, the amount ofcalcium in the minerals is between about 4,000 ppm and about 8,000 ppm.In further embodiments, the amount of calcium in the minerals is betweenabout 6,000 ppm and about 7,000 ppm.

In some embodiments, a v/v ratio of hemp to minerals is about 1:100 toabout 1:1. In other embodiments, the v/v ratio of hemp to minerals isabout 2:100 to about 1:1. In some embodiments, a percent v/v of water tothe combined hemp and at least one mineral is about 1% to about 30%. Insome embodiments, the hemp has a length between about 1 inch and about 5inches. In some embodiments, the composition has an average compressivestrength of about 25 PSI to about 2,500 PSI. In some embodiments, thecomposition has an R-value of about 2 to about 60.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing is a summary, and thus, necessarily limited in detail. Theabove-mentioned aspects, as well as other aspects, features, andadvantages of the present technology are described below in connectionwith various embodiments, with reference made to the accompanyingdrawings.

FIG. 1 depicts a photograph of one embodiment of a sprayable hemp-basedcomposition.

FIG. 2 depicts a photograph of the fire resistant properties of thesprayable hemp-based composition of FIG. 1 .

FIG. 3 depicts a mineral composition of a sprayable hemp-basedcomposition of FIG. 1 .

FIG. 4 depicts an average compressive strength of a sprayable hemp-basedcomposition of FIG. 1 .

The illustrated embodiments are merely examples and are not intended tolimit the disclosure. The schematics are drawn to illustrate featuresand concepts and are not necessarily drawn to scale.

DETAILED DESCRIPTION

The foregoing is a summary, and thus, necessarily limited in detail. Theabove mentioned aspects, as well as other aspects, features, andadvantages of the present technology will now be described in connectionwith various embodiments. The inclusion of the following embodiments isnot intended to limit the disclosure to these embodiments, but rather toenable any person skilled in the art to make and use the contemplatedinvention(s). Other embodiments may be utilized and modifications may bemade without departing from the spirit or scope of the subject matterpresented herein. Aspects of the disclosure, as described andillustrated herein, can be arranged, combined, modified, and designed ina variety of different formulations, all of which are explicitlycontemplated and form part of this disclosure.

Although “sprayable” compositions are described herein, one of skill inthe art will appreciate that the compositions described herein may alsobe molded, poured, cast, or otherwise shaped or applied. Suchcompositions shall not be construed to be limited to spray applications.

As described herein, sprayable hemp-based concrete compositions(described herein as “hemperete”) is a powerful and versatileconstruction material. Hemperete can offer reliable structural support,powerful insulation, and fire-resistant properties while being far morecarbon neutral than purely mineral materials, but it is traditionallydifficult to work with. As discussed above, hemperete has historicallybeen poured into molds or frames to form bricks or slabs that areinstalled upon curing, a process which has limited the material'sadoption in broad construction use. The sprayable material describedherein retains hemperete's general advantageous properties whiledramatically improving its workability by enabling its application withstandard material sprayer devices. This both expands the range of usesfor hemperete and decreases its labor costs. Across numerous embodimentsdescribed herein, the sprayable hemperete can function in a variety ofroles, including, but not limited to, as an interior insulation and asan exterior surface, as well as for more niche uses such as a custominsulation coating for pipes and plumbing.

Preparation of hemp. Industrial hemp (a cultivar of the species Cannabissativa) is chopped while in the field; then the cannabinoids in the hempare extracted. This resulting hemp product (i.e., hemp hurds or shives)is then milled (e.g., with a hammer mill, a chopper, or a grinder) toproper length based upon the desired end product. The proper length ofthe hemp may be substantially or about 0.5 inches to about 10 inches;about 1 inch to about 10 inches; about 1 inch to about 5 inches; about 2inches to about 9 inches; about 2.5 inches to about 8.5 inches; about 4inches to about 6 inches; about 5 inches to about 10 inches; about 4inches to about 9 inches; about 3 inches to about 8 inches; about 0.5inches to about 2 inches, etc. For applications wherein the hemperetewill be hidden by exterior surfaces (e.g., as interior insulation), a“coarser” or longer hemp length can be used such as, but not limited to,from about 2 inches to about 6 inches, from about 2 inches to about 4.5inches, and from about 2 inches to about 3 inches. For applicationswherein the hemperete will be the visible top exterior surface (e.g., asa wall or floor surface), a “finer” or shorter hemp length can be used,such as, but not limited to, from about 0.5 inches to about 2 inches,and from about 0.5 inches to about 1 inch.

In any of the compositions described herein, the hemp can be wet hemp(i.e., plant product that has not undergone any procedure to remove orsubstantially reduce its water content). In alternative embodiments, thehemp can be dry hemp. In various embodiments, dry hemp can be plantproduct (e.g., hemp hurds or shrives) that has been dried according to avariety of procedures to remove or substantially reduce its watercontent. Techniques to dry hemp can include, but are not limited to, sundrying or with a hemp or other plant drier apparatus.

Compositions. In some embodiments, as shown in FIG. 1 and FIG. 3 (theresults of a soil test performed on a hemp-based composition for themeasurement of various chemical elements), a composition includes: hemp;at least one mineral; and water. For example, the at least one mineralcomprises one or more of: potassium, magnesium, calcium, and acombination thereof. In other embodiments, the minerals comprise allthree of potassium, magnesium, and calcium. In further embodiments, theminerals additionally comprise phosphorus. The one or more of potassium,magnesium, calcium, and phosphorus minerals can be provided from avariety of sources in many embodiments. In many embodiments, the calciumminerals are calcium oxides with or without calcium carbonate. Inalternative embodiments, other minerals containing calcium can beemployed. In some embodiments, the magnesium minerals are magnesiumoxides with or without magnesium carbonates; although in alternativeembodiments, other minerals containing magnesium can be employed. Insome embodiments, the potassium minerals are potassium silicates;although other minerals containing potassium can be employed inalternative embodiments. In some embodiments, the phosphorus compoundsemployed are various phosphorus oxides (e.g., phosphorus pentoxide);although other minerals and compounds containing phosphorus can beemployed in alternative embodiments. In other embodiments, the mineralscomprise lime. In still other embodiments, the minerals comprisehydraulic lime. In still other embodiments, the minerals comprise cementcomprising one or more of: concrete, mortar, stucco, grout, or acombination thereof (e.g., Portland cement).

In any of the preceding compositions, a pH of the at least one mineralis between about 7 to about 11, about 7 to about 10; about 8 to about 9;about 8 to about 11; about 6 to about 9; about 7.5 to about 9; about 7.5to about 8.5; etc.

In any of the preceding compositions, an amount of potassium in theminerals is between about 25 ppm to about 100 ppm, about 25 ppm to about75 ppm; about 55 ppm to about 65 ppm; about 50 ppm to about 60 ppm;about 50 ppm to about 70 ppm; about 50 ppm to about 100 ppm; about 45ppm to about 75 ppm; etc.

In any of the preceding compositions, an amount of magnesium in theminerals is between about 250 ppm to about 600 ppm; about 250 ppm toabout 500 ppm; about 300 ppm to about 400 ppm; about 200 ppm to about600 ppm; about 325 ppm to 375 ppm; etc.

In any of the preceding compositions, an amount of calcium in theminerals is between about 6,000 ppm to about 7,000 ppm; about 3,000 ppmto about 9,000 ppm; about 4,000 ppm to about 8,000 ppm; about 6,250 ppmto about 6,750 ppm; etc.

In any of the preceding compositions, an amount of phosphorus in theminerals can be about 0 ppm to about 10 ppm as measured by the Bray-P1method for performing soil tests. In further embodiments, an amount ofphosphorus in the minerals can be about 0 ppm to about 5 ppm as measuredby the Bray-P1 method. In still further embodiments, the amount ofphosphorus in the minerals can be about 1 ppm as measured by the Bray-P1method.

In some embodiments, the composition can be about 25 ppm to about 100ppm of potassium, about 250 ppm to about 600 ppm of magnesium, and about3,000 ppm to about 9,000 ppm of calcium. In other embodiments, thecomposition can be about 25 ppm to about 75 ppm of potassium, about 250ppm to about 500 ppm of magnesium, and about 4,000 ppm to about 8,000ppm of calcium. In other embodiments, the composition can be about 50ppm to about 70 ppm of potassium, about 300 ppm to about 400 ppm ofmagnesium, and about 6,000 ppm to about 7,000 ppm of calcium. In stillfurther embodiments, the composition can be about 59 ppm of potassium,about 330 ppm of magnesium, and about 6550 ppm of calcium. In stillfurther embodiments, the composition can be about 59 ppm of potassium,about 330 ppm of magnesium, about 6550 ppm of calcium, and about 1 ppmof phosphorus as measured by the Bray-P1 method.

In any of the preceding compositions, the v/v ratio of hemp to minerals(e.g., calcium, magnesium, potassium, phosphorus, lime, hydraulic lime,cement or Portland cement, etc.) is about 1:100 to about 1:1; about2:100 to about 1:1; about 5:100 to about 1:1; about 25:100 to about 1:1;about 50:100 to about 1:1; about 75:100 to about 1:1; etc. In otherembodiments, still other ratios can be used, both as w/w and v/vproportions.

In any of the preceding compositions, the percent v/v of water to thecombined hemp and minerals is about 1% to about 30%; about 5% to about30%; about 10% to about 20%; about 15% to about 30%; about 15% to about25%; about 2.5% to about 10%; etc. In some embodiments, the percent v/vof water is dependent on the use case for the composition. For example,a higher percent v/v of water may be used for spray insulationapplications (e.g., pipe wrap insulation), while a lower percent v/v ofwater may be used for wall formation applications, for example withinframes or molds. In some embodiments, the composition can have a slump(as measured with a standard slump cone as appreciated by those of skillin the art) of about 0 mm to about 12 mm. In other embodiments, thecomposition can have a slump of about 0 mm to about 10 mm. In furtherembodiments, the composition can have a slump of about 0 mm to about 5mm. In still further embodiments, the composition can have a slump ofabout 0 mm to about 1 mm. In additional embodiments, the composition canhave a slump of about 5 mm to about 10 mm.

Application of composition. As described elsewhere herein, in someembodiments, a hemp-based composition may be sprayed or otherwisedeposited onto a surface or into an at least partially enclosedreceptable to form a hardened or solid end product. The composition isconfigured to pass through an orifice of the sprayer nozzle. The sprayequipment applies pressure to the composition which allows thecomposition to be sprayed and applied to a desired surface or area.Examples of a commercial spraying machine that can be used include anIMEER Silent 300 Pumping/Spraying/Mixing Machine.

Curing process. After application or deposition of the composition, thecomposition is cured or hardened by, for example, natural evaporation ofwater in the composition; application of heat, for example via anexternal device; application of ultraviolet light; or any other methodknown to one of skill in the art. In some embodiments, one or moreheated water coils may be embedded into the composition after spraying,pouring, or otherwise applying the composition to expedite the curingprocess.

Composition characteristics and features. Depending on the sequence ofthe spray machine, any of the compositions described herein can besprayed or otherwise applied at a rate of about 10,000 square feet toabout 30,000 square feet per hour; about 5,000 square feet to about25,000 square feet per hour; about 5,000 square feet to about 20,000square feet per hour; about 15,000 square feet to about 25,000 squarefeet per hour; about 18,000 square feet to about 23,000 square feet perhour; etc. Depending on the surface that the composition is beingapplied to, a percent volume/volume water may be adjusted to capture thecorrect slump for the application. In some embodiments, any of thecompositions described herein may serve as a replacement for buildingmaterials, such as, for example, stucco and dry wall. In someembodiments, any of the compositions described herein may replace sprayfoam that is applied inside a wall for insulation. In some embodiments,any of the compositions described herein may serve as “pipe wrap,” forexample as pipe insulation.

In some embodiments, any of the compositions described herein may have avolatile organic compound (VOC) level of about or substantially zero. Insome embodiments, the composition can have a VOC level less than orequal to about 10 ppm. In other embodiments, the composition can have aVOC level less than or equal to about 1 ppm. In still other embodiments,the composition can have a VOC level less than or equal to about 0.5ppm. In some embodiments, any of the compositions described herein mayhave a carbon footprint of about or substantially zero. In someembodiments, any of the compositions described herein may have anaverage compressive strength of about 25 PST to about 5,000 PSI; about25 PSI to about 2,500 PSI; about 50 PSI to about 5,000 PSI; about 100PSI to about 1,000 PSI; about 100 PSI to about 500 PSI, about 1,000 toabout 2,500 PSI; about 2,000 PSI to about 3,000 PSI; about 2,500 PSI toabout 5,000 PSI; about 1,500 PSI to about 3,000 PSI; about 1,500 PSI toabout 2,500 PSI; etc. A non-limiting example of an average compressivestrength of a hemp-based composition is shown in FIG. 4 . In thisnon-limiting example, the material expressed a compressive strength of240 PSI. This demonstrates a marked improvement over standard insulationmaterials, which have an average compressive strength of about 30 PSI.In some embodiments, any of the compositions described herein may havean R-value of about or substantially 2 to about 60. This demonstrates amarked improvement over standard concrete, which generally scores anR-value of about 1.98. In some embodiments, any of the compositionsdescribed herein may be fire resistant, as measured by an AmericanSociety for Testing and Materials (ASTM) 84-19B Test or similar test(e.g., ASTM 84-19A, ASTM 84-20, etc.). In other embodiments, thehemp-based compositions can score from about 0 to about 1 on the ATSM84-19B Test. In some embodiments, the hemp-based composition scores azero (0) on the ASTM 84-19B Test, which is a perfect score indicatingmaximal fire resistance according to the test. A non-limiting example ofa fire-resistant hemp-based composition is shown in FIG. 2 . In someembodiments, any of the compositions described herein are biodegradable.

As used in the description and claims, the singular form “a”, “an” and“the” include both singular and plural references unless the contextclearly dictates otherwise. For example, the term “mineral” may include,and is contemplated to include, a plurality of minerals. At times, theclaims and disclosure may include terms such as “a plurality,” “one ormore,” or “at least one;” however, the absence of such terms is notintended to mean, and should not be interpreted to mean, that aplurality is not conceived.

The term “about” or “approximately,” when used before a numericaldesignation or range (e.g., to define a length or pressure), indicatesapproximations which may vary by (+) or (−) 5%, 1% or 0.1%. Allnumerical ranges provided herein are inclusive of the stated start andend numbers. The term “substantially” indicates mostly (i.e., greaterthan 50%) or essentially all of a device, substance, or composition.

As used herein, the term “comprising” or “comprises” is intended to meanthat the devices, systems, and methods include the recited elements, andmay additionally include any other elements. “Consisting essentially of”shall mean that the devices, systems, and methods include the recitedelements and exclude other elements of essential significance to thecombination for the stated purpose. Thus, a system or method consistingessentially of the elements as defined herein would not exclude othermaterials, features, or steps that do not materially affect the basicand novel characteristic(s) of the claimed disclosure. “Consisting of”shall mean that the devices, systems, and methods include the recitedelements and exclude anything more than a trivial or inconsequentialelement or step. Embodiments defined by each of these transitional termsare within the scope of this disclosure.

The examples and illustrations included herein show, by way ofillustration and not of limitation, specific embodiments in which thesubject matter may be practiced. Other embodiments may be utilized andderived therefrom, such that structural and logical substitutions andchanges may be made without departing from the scope of this disclosure.Such embodiments of the inventive subject matter may be referred toherein individually or collectively by the term “invention” merely forconvenience and without intending to voluntarily limit the scope of thisapplication to any single invention or inventive concept, if more thanone is in fact disclosed. Thus, although specific embodiments have beenillustrated and described herein, any arrangement calculated to achievethe same purpose may be substituted for the specific embodiments shown.This disclosure is intended to cover any and all adaptations orvariations of various embodiments. Combinations of the aboveembodiments, and other embodiments not specifically described herein,will be apparent to those of skill in the art upon reviewing the abovedescription.

What is claimed is:
 1. A method of applying a sprayable hemp-basedconcrete composition, the method comprising: spraying a hemp-basedconcrete composition on a surface, the hemp-based concrete compositioncomprising: hemp, at least one mineral, and water.
 2. The method ofclaim 1, wherein the surface is an exterior surface of a building. 3.The method of claim 1, wherein the surface is an interior surface of abuilding.
 4. The method of claim 1, wherein the surface is a pipesurface for pipe insulation.
 5. The method of claim 1, furthercomprising curing the hemp-based concrete composition.
 6. The method ofclaim 5, further comprising applying heat to cure the hemp-basedconcrete composition.
 7. The method of claim 5, further comprisingapplying ultraviolet light to cure the hemp-based concrete composition.8. The method of claim 5, further comprising embedding one or more coilsin the hemp-based concrete composition, wherein the one or more coilsare configured to receive heated water therethrough.
 9. The method ofclaim 5, further comprising determining an average compressive strengthof the cured hemp-based concrete composition to be about 25 PSI to about2,500 PSI.
 10. The method of claim 5, further comprising determining anR-value of the cured hemp-based concrete composition to be about 2 toabout
 60. 11. The method of claim 1, further comprising spraying thehemp-based concrete composition at a rate of about 10,000 square feet toabout 30,000 square feet per hour.
 12. The method of claim 1, furthercomprising spraying the hemp-based concrete composition at a rate ofabout 5,000 square feet to about 25,000 square feet per hour.
 13. Themethod of claim 1, further comprising spraying the hemp-based concretecomposition at a rate of about 15,000 square feet to about 25,000 squarefeet per hour.
 14. The method of claim 1, further comprising sprayingthe hemp-based concrete composition at a rate of about 18,000 squarefeet to about 23,000 square feet per hour.
 15. The method of claim 1,wherein a percent v/v of water to the hemp and the at least one mineralis about 15% to about 25%.
 16. The method of claim 1, further comprisingdetermining a slump of the hemp-based concrete composition to be about 0mm to about 12 mm.
 17. The method of claim 1, wherein the at least onemineral comprises one or more of: potassium, magnesium, calcium, orphosphorus.
 18. The method of claim 17, wherein an amount of potassiumin the at least one mineral is between about 25 ppm and about 100 ppm.19. The method of claim 17, wherein an amount of magnesium in the atleast one mineral is between about 250 ppm and about 600 ppm.
 20. Themethod of claim 17, wherein an amount of calcium in the at least onemineral is between about 3,000 ppm and about 9,000 ppm.
 21. The methodof claim 1, wherein the hemp-based concrete composition furthercomprises one or more of: lime, hydraulic lime, concrete, mortar,stucco, grout, or Portland cement.
 22. The method of claim 1, wherein apH of the at least one mineral is between about 7 and about
 10. 23. Themethod of claim 1, wherein a pH of the at least one mineral is betweenabout 7.5 and about 8.5.
 24. The method of claim 1, wherein a v/v ratioof the hemp to the at least one mineral is about 1:100 to about 1:1. 25.The method of claim 1, wherein a v/v ratio of the hemp to the at leastone mineral is about 2:100 to about 1:1.